Portable electrical spot welder



May 4, 1954 w. B. FAHRENBACH 2,677,744

PORTABLE ELECTRICAL SPOT WELDER Filed April 27, 195o e sheets-sheet r "il" I J WOLFGANG B. FAHRENBACH INVENTOR.

BY I

/roR/VEY May 4, 1954 w. a. FAHRENBACH TABLE ELECTRICAL SPOT WELDER POR 6 Sheets-Sheet 2 F'iled April 27, 1950 FIG. 4

""Illlll IIlIIIIIIIIIIIIIIIIIIIIL F/G. 5a

vWOLFGANG B. FAHRENBACH INVENTOR.

May 4, 1954 w. B. FAHRENBACH 2,677,744

PORTABLE ELECTRICAL SPOT WELDER Filed April 27, 1950 6 Sheets-Shea?I I5 WOLFGANG B. FAHRENBACH INVENTOR.

TTRNEY May 4, 1954 w. B. FAHRENBACH 2,677,744

PORTABLE ELECTRICAL sPoT wELDER Filed April 27, 1950 6 Sheets-Sheet 4 lso" 32 WOLFGANG B. FAHRENBACH INVENTOR.

May 4, 1954 w. B. FAHRENBACH 2,677,744

PORTABLE ELECTRICAL sPoT wELnER Filed April 27, 1950 6 Sheets-Sheet 5 uw une In um WOLFGANG B. FAHRENBACH INVENTOR.

A T TOR/VE Y 6 Sheets-Sheet 6 Filed April 27. 1950 MNST* WOLFGANG B FAHRENBACH INVENTOR.

ATTORNEY Patented May 4, 1954 UNITE-D STATES ?ATENT OFFICE 2 Claims.

The invention relates to hand portable electrical spot Welders of the gun type which embody a transformer in the hand carried and manipulated unit.

It is one of the objects of this invention to provide a Welder of general utility. Since general utility for a hand tool of this character is affected by many considerations, this general objective is served by several unique features of utility, some of which are also applicable in other electrical welding machinery, though possibly with not so many benefits.

Accordingly it is a further objective to provide arrangements of components such that the weight of the tool is minimized. Another object is to effect a reduction in cost of manufacture and operation of such tools.

An additional objective is to provide a tool of improved flexibility in use, both as improving the dexterity of the operator and as extending the types of jobs for which the tool is tted.

These and other general and particular objectives will be evident to those skilled in the art from a consideration of the following specication, claims, and accompanying drawings.

In the drawings:

Fig. 1 is a somewhat schematic longitudinal section through a Welder;

Fig. 2 is a fragmentary perspective of a modiiication of a detail of a Welder;

Fig. 3 is a fragmentary view showing a further detail;

Fig. 4 is a somewhat schematic diagram of a controller for the Welder;

Fig. 5 is a somewhat schematic longitudinal section through parts of a modified Welder;

Fig. 5a is a section at plane 5dr-5a of Fig. 5;

Figs. 6 through 9 illustrate various modications and details;

Fig. 10 illustrates an adapter for use in butt Welding;

Figs. 11 and 12 illustrate special electrode and horn structure for the lap welding of broad sheets, as to which a foreign patent application filing date applies;

Fig. 13 is a somewhat schematic longitudinal section through a. modified Welder as to which another foreign patent application ling date applies;

Fig. 14 is a somewhat schematic illustration of details as to which a third foreign patent application .idling date applies;

Fig. 15 is a somewhat schematic illustration of a further detail as to which a fourth foreign patent application filing date applies;

Fig` 16 is a somewhat schematic illustration of a further detail as to which a fth foreign patent application filing date applies;

Fig. 17 is a section through the main body of a further modiiication of a welding machine of the portable type, especially designed for light weight through the employment, among other things, of high frequency current and high fluid pressures or high air pressures;

Fig. 18 is a section at plane I8--I8 of Fig. 17;

Fig. 19 is a view on the approximate planes shown oiset on the broken line I9-l 9 of Fig. 18;

Fig. 20 shows a modification of a detail for the device of Fig. 17;

Fig. 21 shows alternative details for the motorization and cooling and induction thrust member for the Welder of Fig. 17;

Fig. 22 represents a cross section of Fig. 21 along with modifications of the fixed portions of the secondary winding to be embodied with it; and

Fig. 23 illustrates a further modification of the portable welding tool as applied with a monorail carrier system and provided with different types of motor and iiuid control devices.

Referring now to Fig. 1 the apparatus there shown comprises a transformer core 2G which is shown to be of the shell type having three legs 22, 2li, and 26 formed of laminations and clamped together in a conventional manner, but particularly to provide two windows 25 and 2B whose cross sections in planes perpendicular to the drawing sheet, are preferably of uniform areas and uniformly placed along the axes of these Windows. These windows from passages for the free reciprocation therethrough of a thrusting element 3o for the moving welding tip 32 both of which parts are hereinafter further and more particularly referred to. In addition the windows 2t and 28 provide a space for the winding on one or both sides of a thrusting element 323 and around the center leg 24, of the primary current Winding i to which current is conducted by a suitable iiexible electrical cable 35 in a conventional manner, and also of a secondary current winding as will be more particularly pointed out.

1t is deemed a substantial advantage in itself to so arrange the core of the transformer that the thrusting member passes through a hole in the transformer because by this means in many instances the shape and balance of the gun may be much improved and the mechanism for its operation much simplified. Whether the hole through the transformer be one which is a conby the fluid is opposed by e. return Spring t2 engaging the bese emi the element 3Q shown. im addition to s uneton of transmitting the im?. from piston through the transformer formed in th suit i te the the thrust eemezit Si! is also extra v designed to f@ n e substentie portion of the thrust element ftransformer seeeruary current in i :ter and Weld to a eonduetor. n g. l the portions and carre of thrust elearent ferm o tiretey one ci of total seconder] eu ent W" i'ng ou? the transformer. The balance er" the W elucies en inten ai rig; e riem @It Wlreh passes es e threugii and. reeipreeates "irlow of the core es et the lefcller. eutet iereof in a m joined pim/ide@ thre,

Inasmueh primary winding after censtruetom they together r' to which the 0"' 'le terminal portieri te termi el i" When the 1 1g a v ze eemeressed against ether "ating for members e? vrfimary for positioning respect to tion shown terminal i corre and in e, alignment ai.

agir tip portion ai g' weleied, t n 52, and termi el is prei?u provided with a, centra?.

E te prevent e rrent from er. th@ helder and l the horn e@ is shown to Tee mmm the eyiir riem portion and fastened with a clamping alignment with the of th Z of the eore.

The electrical tern massive not only bee u current but aise heee 33 and eer@ im 1 0 5. Furthermore the tel f ng ing and. supper@ for 'the tip t rust ees preferrei te es illuetretec' e e horn 4G n tion or; the Y positron and sur- :eh e ree member away from the ste by the wel( het the vding am opening ing part M of the cproeebe towar er welding tip carrie It Will now be eler me it, mund" ig thy. eireuit,

which the me @er be 'fed and second from fon-neg by the horn 1y se more tcuary poi?. er?. em the horn t@ may mation shown sont nue-us Q and as smh uiiy enthe thrust ele ne; tion para) e1 W. bearing part movement is l bearing part made as long es .1 f it to with the need 0f ether t is a unique feat; thruster externes thr walls, cui @ieee the ing En i eher valve the bellows centree n .1, "4 @man eed di e is, te respectively zur the tool mi is attache; t@ gm i hou t v 1 nreeiated fresh air Corning im ceci.

te escape et @zeil operates the thrusteeoling; of the windings and ei,

have shown e ma 'or the tram.

1e fulletion of thi ming te .teeomary Fig. 1 bemg pr The uif mete or th '1 purpese. by fluit' preseure i f master01/e :is Py port eis and transmitting of 'the The movement of bellows lovable turLs is for the purpose of keeping the weightv of the body which has to be pushed by the hydraulic fluid in the bellows 52 to a bare minimum such as in the Fig. 1 construction, yet the winding gives a larger value of secondary induced voltage than is possible in the Fig. l situation, assuming the same number of turns in the primary winding 34.

Since approximately only one turn is moved the inertia and speed of response to the action of the bellows found in Fig. 1 is maintained at the desired low inertia value and high speed value, often required of a tool of this character. The construtcion in Fig. 2 comprises the moving thrust member 30 and its extension 64'. Two additional full coils 86 and 88 surround the core leg 2t (the core being omitted in Fig. 2), but coils 86 and 88 are rigidly fastened immovably with respect to the core legs, and the terminal ends S0 or the coils 86 and 88 are rigidly fixed to the terminal 42 of Fig. 1. The end terminal 55 of section 53, being movable, is joined to the ends 02 of the fixed secondary coil sections by nexible conductors 94. The two coils S6 and 88 together form only about one turn composed of two parallel current paths. illustrated a mechanical guiding detail for maintaining the moving inductor-conductor-thrust transmitter 30 in a fixed path free of binding and electrical engagement with the adjacent portions of coils 86 and 8B in Fig. 2, or of the primary winding 34 in Fig. 1. I provide a rectangular trough 05 in each side of the reciprocating member 30. Each trough is partially occupied by a roller 03, which is of electrical insulating material having a diameter greater than the depth of the trough. The rollers need not normally engage the adjacent inductors 85 and 08, but in the event the moving inductor is deiiected by the heavy current it carries or is slightly bowed by ends thrust upon it, the rollers 08 prevent I Contact between the moving and the thrust member and adjacent coils and themselves offer a minimum amount of friotional resistance.

ln Fig. 4 I have illustrated somewhat schematically a manual controller, mounted on or partially in the housing 40, with which the iluid flow in bellows 52 and the current to the transformer primary winding 3d is controlled. This controller performs the several functions of closing the inlet to 58 when the tool is not in use; fully opening the outlet 50 when the weld is completed so that the return spring 62 withdraws the tip 32 without opposition from the bellows 52; admitting the fluid into bellows 52; and to either permit the maintenance of a selected effective pressure in the bellows while uid flows or to apply the full unit pressure of the source 58 within the bellows.

To effect these various purposes and results the controller comprises two valves |00 and 102 linked by a common operating device including hand engaged actuating lever arm |04 and an intermediate lever |05, both having a common fixed pivot |06 on frame 40. Adjustable thrust pins |00 and H0 carried on lever |05 determine the respective closures, and the relative degrees of closure, of valves |02 for any position of hand lever lili. The levers |04 and |05, through a certain range of movement of lever |04, are connected in a manner to move as a unit, the connection here being shown to include an appropriately stift coil spring |09 positioned between the levers and threaded over a pin |03 passing through an opening in lever |04 and having a head |01 to engage the lever |04 with the other end of the pin iixed, as by threading, to lever in Fig. 3 I have |05. A stop lug formed integral with lever |05, works between limit screws H4 and ||6 adjustably threaded in suitably provided portions of frame 40. The hand lever |04 is returned by a spring H2. The stop ||6 stops the movement of lever |05 in its direction of closure for valve |02 and opening for valve |00 and when lug engages stop H5 the degree of closure of valve |02 is determined by the setting of screw I0. At this position also, the adjustment screw |08 through lever |05 determines the degree of open ing of valve |00. The difference between the areas of the inlet and outlet openings provided by valves |00 and |02, and the sustained pressure at 58, determine the pressure within bellows 52, yet iluid continues to now therethrough, and although not shown in Fig. 4, it is evident that the fluid may be additionally directed through cooling channels in a manner presently to be described in reference to other ngures of the drawing.

It will be clear that the adjustment of pin |08 may be such that valve |00 is either fully closed when return spring |2 is fully released, in which case spring 62 has no opposition from bellows 52; or the valve |00 may be partly open and valve 02 fully open, in which case only slight and therefore ineffectual opposition to spring 62 is offered, yet the fluid flowing is active for cooling purposes when current is not ilowing in the inductor 30. This cooling function will be further referred to,

When valve |02 is closed, or partially closed, the pressure builds up in bellows 52 and drives the actuator 30, as such, to clamp the pieces 1i) between tips 32 and 50. However, this movement may, and usually does, terminate before pressure in bellows 52 becomes adequate to apply an ade ouate clamping force to tips 32 and 50. Such adequate clamping force is determined by the contact resistance between the parts to be welded and should be applied before welding current flows so that a smaller minimum period of current now will suffice to effect the weld and because the voltage for initiating current flow required of the transformer is reduced by such application of pressure before the weld current flows.

It is desirable that the operator have ready `control of the circuit to the primary winding. Accordingly, after lug engages stop H6, further movement of lever 04 is permitted by compressing spring `|09. This movement results in the closure of a switch to control the circuit of the transformerl winding 35s. A self-adjusting switch contact ||1 is carried on arm |04 by pin H9 and spring |03, positioned to engage xed contacts H3 and ||5 in the circuit of primary winding 34 only after lug ||1| has engaged stop i5, or after valve |02 has closed. The closure of switch H1 across contacts H3 and H5 conditions the circuit of the primary winding for control by the pressure condition-s at tips 32 and 50, yet leaves the circuit under control of the operator as respects the determination of the time during which current may now subject always to the continuance of the proper hydraulic pressure.

It is important to notice that the force exerted on the welding tips is the same at all points in the movement thereof and that after welding starts the welding tips are forced into the softening metal to improve the contact and maintain a high welding tip pressure.

A second pair of contacts |2| and |23 in the circuit of the primary winding 34 are caused to pass current by a pressure responsive switch contambor ila recel of bellows Tl closed only when a detsimnefl the ie wies the wall portion |44 g transformer by me wall portion M4 is sleeve I 122 through the by the presso Wl ich, it may be noted, @sin wizliitlicbol.. ,l of flaring, be brought snugly miilizium l en s of the djacent primary coils Well f orme@ vof a, plate to lieeoy resve switch iall lengoh of the tool. Any horn, has@ il ACC of ju@ each VJ H25 elie- @eve U58 sup oi end of frame w il potion IM Sup- @Cim to above loir'u l is cylinder tional useful it that the memaiiy Suitable si and. may lm? than movido i continuous piefeired in folie moving enterlieoause off@ i one core oofe oiei motor in leciplocaton. int shown "teh desirable flows, Well, mii; period of welding ooi ii-olla? i yfiauic actuating sind p water whose Qiesmu'e le value of unil;

wat, aitl oiilyarels-Livel'ysr l 1 Y un lille?, like m out genero/taal in *in-V- y v meremial pressure the hem :is whore i' .w is encoun in addition.

veld position. f of pressui'e be of low unit i uid full 1 ifeescnpes into t parte. the

In Fig. 5 a, r vde primal f L bein# observed. that ille large to welding tip is infor the s'oluctuie. The thrust iiom end. to end min marl pipe wl? ,1 is xefl to the e is also The It -noves ffl/'miie extends to a i straight and .3 the fango 0; 'movement of tile f1-om e' iii iii@ which foi-ms the en in tube The incoming woe mixmail H52 -orresponmlig to teini1al in 75 in tube i12@ :surrounding the straight pipe.

our'

The circulation is therefore provided by the two straight concentric tubular members |36 and |63 which function uniformly irrespective of the fact that they are relatively movable. It will be observed that the cooling is also operative on the insulating bearing |48 to preserve its qualities.

In the foregoing described structure it may be observed that the ring core seems to have a length advantage over the shell core. This advantage may, however, be attained in the shell core construction of Fig. 1, for example, by aligning the terminal 42 and thrust member 3c in a straight line with, say, window 26 so that the thrust member is straight as in Fig. 5.

Reference has been made in the foregoing to the interchangeability of Welding tip horns. The utility of this interchangeability is illustrated in drawing Figures 6 through 12. In Fig. 6 a long horn 46a is shown. To a tubular tip holder such as |36 in Fig. 5 there is secured an externally tapered adapter dit having a central passage. A hollow extension tip holder it is secured to adapter 44. The tube |23 of Fig. 5 is threaded into the base |52 and may be removed and replaced from the tip end of the tube. Accordingly a tube, like tube |53 but enough longer to reach near the left or tip end of extension 49, is readily assembled when the extension is to be used. Such a long horn ded is adapted to operations such as welding discs to close the ends of relatively long tubes.

Figs. 7 and 8 show a horn 4Gb providing for separable tip holders of, respectively, the straight and offset types, and illustrates the detail fastening or the horn 46h to include a nut fle bearing in a tapered eye of the horn and threaded onto the terminal |42.

In Fig. 9 the movable tip |86 is carried on a rocker |68 pivoted on a hornlike offset Vit. Rocker |68 is rocked by the thrusting inductor itil, a suitable linkage being provided at H2, the rocker |68 being electrically insulated by an insulating bearing sleeve |13 from i'iil and electrically connected to the inductor by suitable nexible conductors.

In Fig. 10 there is illustrated an adapter apparatus for joining the ends of two strips oi metal, such as wires 326 and 328, by welding their ends together end on. This style of welding is termed butt welding and presents, among other things, the distinct problem of grasping the two parts separately and then forcing their ends together, which problem is somewhat distinct from that or lap welding as it is illustrated in Fig. l because, due to the shape of the strips, each part must be independently grasped while being forced against the other part.

The joining of the tips of wires together is uniquely a problem for portable apparatus because such joints are continually being made at points of installation of electrical and other apparatus involving Wires and strips of metal. It will, however, be evident that any of the portable apparatus here shown may as well be set up in a fixed location, as in a factory, or the principles of this invention may be applied in appropriate situations involving relatively immovable apparatus.

Ihe illustrated apparatus comprises a horn member 46c secured to the terminal 42 as in other cases. On the horn 46c there is fixed a device 322 embodying a clamp, having a clamp handle 323, for grasping one wire 328 and holding it in a rigid position with respect to the horn. This clamp is electroconductively integral with the terminal #l2 through the device, not shown, by which horn 45C is detachably secured to terminal 42. Fixed on the horn is a member providing a reciprocative slidevvay for a reciprocable clamp device iii embodying a clamp handle 355. This reciprocable clamp grips the wire 323 and positions it in axial alignment with the end and axis oi wire 32d, and the reciprocable clamp is guided by slideway 324i so that the wire ends when moved together will abut end on. A spring, not shown, is provided to separate the reciprocable clamp device from 322 when arm 3|5 or 323 is released.

The member 326i is constructed, as by having an insulating sleeve slide surface, that the reciprocable clamp Sift is insulated from the horn and clamp device 322. Flexible electrical conductors 3 l2 are suitably joined to a special thrust and current transmitting cap 3|l| which is fixed in electrical contact with member 4|.

A bell crank lever 3i@ pivoted on a pin 3|8 secured on horn 5&5, an insulating sleeve 3|!) serving to prevent current from passing to the horn from the crank. The crank has threaded therethrough a screw 325i for engaging the reciprocable clamp 3M and or adjusting the lost motion therebetween.

'in operation, aiter the wires 326 and 328 are clamped in alignment by the clamps, the member fil is driven by the fluid pressure in the bellows thus causing cap 3| to drive the bell crank in rotation about pin 3|8, the crank in turn causing screw 32u to drive clamp 3M over slideway 32d toward clamp 322.

When the wire ends engage, any motion of the bellows dii ceases and pressure on the abutted ends of the fires builds up to the desired value, after which current is caused to iiow from tip holder lil, through cap 3H), through conductors 3|2 and clamp 3HE, and thence through the tips of wires 326 and 323 to clamp 322 and thence through horn d6 to terminal i12.

in Figs. 11 and 12 I show a horn shaped to provide what I term a throatless tip holder. This holder permits the formation of a seam joint of two large sheets I and |84 having straight edges to be joined, the joined edges of the sheets passing from the tips 32 and 5G toward the observer as he views the device in Fig. 1l, and the body of the sheet adjacent one of the unjoined edges passing over the horn portion at the right and only immediately to the left of the tips as seen in Fig. 11, while the body of the other sheet adjacent its edge passes beneath the portion of the horn at the left and immediately to the right of the tips as seen in Fig. 11, both sheet bodies passing over tip 5i) and under tip 32 where they are joined by the welding current and pressure.

Figs. 1l and 12 illustrate the details of construction of the throatless tip holder as it is detailed in my German patent application G32A=48 filed in the German Patent Office May 29, 1949. The horn has the general shape of slightly more than one turn of a spiral corkscrew, and provides a supporting arrangement for the welding tips such that sheets or" large areas may be Welded along edges between their joined areas over lapjoined areas along said edges. Thus the large areas of the sheets and |82 to be welded, when regarded as approaching the observer (Fig. l1) and the working region between electrodes 32 and 5c in Fig. 11, extend respectively right and let of the centerline |2-|2, and the lapping portions thereof may extend respectively as far awry-i4.

as the internal boundary surfaces lll and Il of the horn; which surfaces as illustratesv are about parallel to eacn other and to tice direction of movement of the two slieets they appreach the electrodes. As in other cases, illustrated specifically in Figs. l, 7 and 23, the base I'lll of the born is provided with an eye liole provided by rotating bearing surfaces concentrici upon an airis generally; parallel to 'the spiral and concentric upon tlie or the movable Welding tip Sil ivliicn bearing .surface is arranged` so that base nts on the terminal it? for fecting rotatable adjustability thereof about the axis of reeiprocation of tips and low electrical Contact resistance between the terminal l2 and horn base ilil when a clamping is to concentric thread g on tlie terminal The transverse cross section oi' the rn body decreases from its base llt toward tbe born point portion llt, to ivliicli the :ernote stationary Welding tip is nrred in line with the path of reciprocat iv ig tip in a manner to give strength of cantilever but with reduction in section and consequent reduction in Weight ot the horn. is is seen more clearly in Fig. l2 the tli less spiral born is more specifically described. as iroviding tlie axially displaced coaxial tip sup b end parts llll joined by which may be regarded coi tional functional component itegral parts, referring to Fig. ll, Wiiicli ci lent parts are: tl'le lateral base extension l'lila which extends from the base part il to como first part of tlie convolution wli li extends somewhat radially from the airis oi' tlie reciprocating electrode; the component fern extension arm lilla which. extends in tpe direction of the spiral axis and in a direction opposite to the direction ol Work to tbe Welding electrodes, tlie transverse arrn lili which extends across the direction of work approach and about perpendicularly across the direction of the spiral tlie transverse arni extension component lilla which extends further in the direction of tbe s irai axis and in tlie direction oi Work approach and the terminal end extension component lla.

The distance between the axis of the electrodes 32-llll and the transverse arin lill in part determines, in inverse proport'. n to such distance, the degree of bending or the streets Hit and and as seen in Fig. l2, cross section of the portion llil is tliicl; at the sheets input side ililu of tlie horn and tapers to a minimum wedge edge Ilb at the side ci the transverse liorn component H5 nearest to tlie welding tips, in this nianner allowing the sheets and to approach the Welding tips in nearly parallel planes and with minimum bending. fis seen in l.y ll, the surfaces llfl and il@ are nearly parallel and about equally spaced from the center-plane of tloe work approach plane lil-l 2. This defines the upper limiting lap of tlie edges of sheets lll@ and |34, and the surfaces lill and lili may serve as sheet edge gauges to insure a uniform guide for the edges of sheets it@ and itil. In so arranging the transverse arm portion Il'li as shown so that its top and bottom surfaces are in planes intersecting in a straight line perpendicular to the. axis of electrodes 32 and ll, those surfaces assist in guiding the sheets in a straight path to the electrodes.

Fig. 13 illustrates a further Inodlication einbodying principles of my invention and is a duse part il@ and i-lilre convolution.

' oi' rive plicate drawing of that in my German patent applications PllA-l led May 29, 1949, and (il-28,865 led May 29, 1%9. in this modification tlie secondary Winding is partly formed by the bearing sleeve and terminal M2 and the ilaring or conical housing portion l e6. The balance of tlie secondary Winding, shown as a total of two turi includes flexible conductors IS which are joined to a reciprocating terminal holder IBB. The thrust member IE5 is a tube s callar to tube itil in 5. primary Winding is shown at IEE', spaced arcuately about the core from the secondary conductors. conductors ISG may be rubber covered to avoid wear and snort circuiting. A. l ne lil@ provides a mounting for the bellows fluid inotor 52 and the pressure and coolinfj Water inlet and outlet connections are slioivn at HP2. The ira-ine further provides' a I 9e in which the nan-d control arm |04' is mounted. lt will be e ent that the flexible secondary conductor portions, It@ tend to coil and. uncoil as tbe thrust member reciprocates. lt Will also be evident that tbe thrust and cooling provisions are siniilar to those provided by the 5 device.

lfl is a duplicate of the drawing in my German tpatent applications Pillltt and G2919? iiled May 29, i949, German Patent Oilice. lilflile the structure different in form, it periorzns similar and/or identical functions with that oi certain 1 of Figs. e and The controller is illustrated in the right hand portion of otive members in the left hand portion. il. con l lever ltd is snoivn in released posit n, some fluid being allowed to pass into the cooling passages via valve IlIl, to cool the electrodes during periods, in the adjustment slioivn. suitable passage 56 is shown so that froid pressure returns the valve to the inactive position. The inductor-tlirust member I is actuated by a slide piston It in a stationary cyli der itil, with a return spring 'ti-.'22 provided.

Fig. l5 is a duplicate oi the drawings in my V rman ypatent applications 144,643 and (529,024 iiled May 29, i949, which snows the movable hollovv tube inductor thrust member l3t and the stationary cooling water inlet tube IED, with electrical insulating bellows ISB and Witli movable Welding tip 32 and return spring 62".

Fig. i6 is a duplicate oi:` the drawings in my German patent applications 1344,900 and, G29,l98 tiled in Germany 3l, 1949, This device is irnilar to in Fig. lll but provides for applying power to squeeze the Welding tips together hydraulically by foot power in the event there is insuicient pressure in the water supply to effect this end.

In the positions of the parte shown, the flow is free and the welding is retracted. The movable valve has been retracted by spring 235. This allows cooling in the manner illustrated in Fig. 5, for example. As the outlet til' in Fig. 16 gradually closes, the thrust member l is moved by the inadequate pressure of the water supply, possibly tlirougn the full stroke of the tip to the Work, but with little force.

Further movement of the valve 2cd closes both the inlet and outlet ports 58 and in Fig. 16 and traps a xed volume of incompressible hydraulic Fluid in the cylind portion 264. Further movement of the pieton 2li@ transmits the force of the foot directly to the bellows motor. It is evident that the stroke and bore of the piston 2&3 and cylinder 2&4 are such as to give both the required volume displacement and unit pres- '13 sure needed to develop the required force. A pressure relief device 206 is also provided to adjustably limit the pressure on the welding tips resulting from foot operation. In this way the tip thrust is controlled.

Figs. 1'7 through 22 illustrate the invention with added or modiiied features such that one or more of several specific problems are solved. For example, where relatively high welding tip forces are required the low pressure of a water supply may be inadequate to produce the required tip pressures with a tool of reasonable size and weight. High water pressure, or a pressure booster may then be used, with a smaller bellows or piston area. The w-eight may also be kept down by multiplying the functions of the secondary winding further so as to replace portions of what otherwise would have to be the framework, the core clamp, and radiating and housing facilities for the internal mechanism. A great exposure of the bare surface of the secondary conductor to the ambient atmosphere, attained by making the exposable part to function as a housing, results in its own lowered operating temperature. Great freedom is attained in this modification for designs to obtain a large cross section of the secondary electrical conductor and in a minimum space yet the metal section is thin at strategic heat dissipating regions and therefore allows the rapid transfer of heat from hot confined regions. These advantages for cooling the secondary winding serve to maintain the resistance voltage drop in the secondary, due to the resistance of the inductor itself, at a minimum value. Therefore a greater portion of the secondary voltage is available to drive current through the parts to be welded. This advantage may, of course, be partially distributed by the designer into reduction of the core section and weight.

In this construction I so arrange and proportion the parts that the driving motor is largely contained within the Window of the transformer. This tends to shorten the axial length of the entire tool and further allows for a substantial increase in the distance through which the movable welder tip' may be driven as compared with the total length of the tool. It will be seen that this construction has been effected in one case by in part making the movable portion of the secondary winding of the transformer a cylinder, and in another case by making the movable part tubular and arranging for it to contain an expansible bellows of many corrugations to allow a considerable longitudinal expansion.

While it appears in the drawings of this construction that the opening through the trans former core is enlarged, such enlargement is only apparent in the drawings for it will be clear that the diameter of the cylinder is required to be only inversely proportional to the fluid pressure delivered within it in order to deliver a certain thrust. The pressure is increased as desired by suitable pressure sources and regulators not here described.

The constructions in the modifications of Figs. 17 through 21 are particularly tted for the employment of relatively high frequency alternating currents, since the design permits a tool weight reduction of as much as one third through increasing the frequency for which the machine is designed from sixty cycles to one hundred and eighty cycles per second.

The portable welding unit of Figs. 17, 18, and 19 comprises an integral member M0 which has several functions, including its primary functions of first being a good current conductor and as such forming a part or" the secondary and welding circuit of the transformer and secondly being of rigid metal to form a strong housing and clamp for the other parts. The member AIE) includes the terminal M2 externally formed to accommodate the various horns as shown in Figs. 7 through l2 and internally tted with an electrical insulating sleeve lil corresponding to sleeve dit in Fig. l, differing in the particular that an annular flange die provides a seat for positioning the sleeve e against axial movement in one direction.

in addition the member dit) provides the flared portion i553 of relatively thin cross section from which extend two parallel arm portions 42d and i222 in a foil like disposition, the inner sides of the arms being joined together by the flared portion terminated at edges Md. The arms :32B and A22 are of arched section transverse their axes to provide clamping edges 426 to engage the edges of the laminations 9,23 of the transformer core and to provide a space 43% between itself and the core within which a portion 32 of the transformer primary winding is protected and contained as well as a space for the free circulation of cooling air. The clamping edges 42E of each arm extend in a common plane toward the narod portion 413 and terminate at abutment edges #i3d which abutment edges extend inward at right angles to edges 425 and form seats for the left end of the stack of laminations 435i. The abutment edges i3d are placed to position the stack away from the portion dit to provide space for the end turns of primary coils 432 and circulation of air. The arched arm sections dit and 22 are extended rightward of the stack :i3d and coils #532 and terminate in a common plane.

As is clearly shown in Fig. 18, the arms 42d and 22 provide an open sided space between them for the reception of the stack 43E. The unwound portions i3d of the lamination stack close the sides oi this space between the right and left pairs of opposed edges d2@ of the arms; except, as seen in Fig, 1'7, for an opening between the edges dit and the rear end ci stack i3d Suitable means, not shown, are provided to iirrnly lodge the core and primary in position between the arms and against their edges and abutinents.

A portion of the secondary winding is provided by a pipe dit@ which extends into the window formed by the core i3d The rightward end of pipe fait is joined to the ends of arms and 22 by flat bars @52 extending upward and downward as shown in Fig. .1.7 from the right end of pipe Mt. The other, or leftward end of the pipe dit in Figs. 17 and 19 has attached thereto two laterally extending conductor bars @im which pass between the arms t2@ and 22 adjacent the edges #i213 or" iiared portion dit and leftward of stack GSS.

Thus it will be observed that one substantially complete turn about the core is terminated by bars ddd. A second turn is commenced by two longitudinal bars 445 which are joined to bars 44d and which extend rightwardiy adjacent core portions @38, strips of electrical insulating material Mi' being interposed between the core and the bars d. The longitudinal bars M5 are pro vided with a terminal portion M8 adjacent the rightward end of stack 436 to which there is joined a flexible conductor 45S which is, in turn,

joined to the movable part of the secondary flap valve to the extent determined by the resulting pressure within the housing During the following welding cycle the remaining air absorbs heat and is subsequently crowded out by the next release of air from the motor. The path for the discharge of such air is illustrated by the curved line 50d in Fig. l, though it is evident that any path into the interior of the housing from the valve will suice. Now it will be appreciated that the Welder mechanism may be entirely enclosed, with but one valve for discharge .of such cooling air from the housing, and no ports available for the admission of air other than that which comes from the compressed air supply. in this way all dust particles, moisture, and like material may be excluded. Y

In Fig. 23 there is shown a tool embodying fea-.- tures in addition to many of those elsewhere illustrated. Particularly, the tool is supported by its core centrally mounted in a rotatable spider 400 having a peripheral circular ball raceway .692 rotatively coupled to a surrounding ring dell having a ball companion raceway 48S through roller balls 4%. An eye 5432 .provides for hanging the tool from an overhead support or monorail system.

The core 22 has secured thereto by through bolts 504 two frame members 506 and 508. The movable secondary 30 is driven by a diaphragm motor 510, a head 5I2 suitably fastening the motor diaphragm to frame member 508. The head 5I2 includes valving chambers over inlet and outlet passages 58 and 60, the valves .including closure diaphragms 5I4 actuated by headed plungers 5l6. The actuating control mechanism for the valves is mechanically somewhat different from that which I have Villustrated in Fig. e although it produces similar effects. A lever 51S is pivotally linked to a second lever 520 on a floating pivot 522 which second lever is pivoted at 524 on valve base 526. A spring |09 and pin |01 hold the lever in fixed relation until lever 520 is stopped in its movement and thereafter lever 518 pivots on pivot 522. The degree of opening of the outlet valve at 60 is adjusted by a thumbpiece 528 having a shank threaded through a yoke 530 straddling plunger 51.4 and disposed in the path of lever 520.

DETAILED FEATURES The foregoing description refers somewhat Electrode structure Various specifically variant provisions are made for mounting the horn or yoke 46 in a manner so that the fixed tip 50 may be fixed in alignment directly on the axis of reciprccation of the axis of movement of the electrode contact tip 32 by plunger 4|. When this alignment is provided for the maximum effective thrust occurs across the work and the neatest spot weld occurs through the shortest current path between tips 32 and 50, and side thrust between bearing surfaces of plunger 4| and insulator sleeve 48 are minimal. There is, under these conditions, no resultantl turning moment about the weld point at the time of exertion of welding pressure particularly if the axis of plunger 4l is held normal or perpendicular to the plane of the work surface, as shownl in Fig. 1. It will be observed also that irrespective of the rotary position of horn 46, the tip 32 serves as an accurate pointer which vis in view of the` operator and-.can therefore b used by the operator to locate the spot on the work where a weld will result upon cycling the pressure and current flow control. Inasmuch as the direction of pointng of the movable electrode is always the same with respect to the balance of the gun, .considerable accuracy may 'be acquired in the placing of the weld by an operator, irrespective of the rotary disposition of the horn on the hornpost.

` Inasmuch as the greater number of the most advantageous features of the electrode structure are illustrated bythe device of Fig. 23, it is now described extensively in detail and material departures therefrom found in other modications will thereafter be referred to.

The electrode structure of Fig. 23 comprises, amongcther things, a separable component part 42, here called .an annular .electroconductive component or an annular pivot and electrical separable terminal .connector post for the horn, a separable companion part 46 constituting the annularly adjustable horn or yoke of the Welder, of which there are many interchangeable styles V shown and equally iittable to the annular or tubular post .42; the reciprocable inductor-conductor-driving plunger 4l, an annular vclamping nut 45, a bearing insulator sleeve 48;, and the fixed electrode .or welding tip 50 fixed on the .free end of horn 46. The annular pix/.ot .and connector post cl2 is generally tubularvand provides apreferably circularly cylindrical external centering surface 42a, intermediate its ends and concentric upon the axis of the post 42. One end of the post cl2 provides an annular flange having a shoulder abut.- ment surface 42h disposed in a plane radial upon the post axis andfacing in the direction of the other end of the vpost 42. The postM provides on the other end 52e thereof'external concentric threading 42d. The tube 42 is reduced in diameter from the flange to the threaded end and provides intermediate the ends thereof an internal annular shoulder .42e disposed toward the flanged end for the seating thereagainst by the plunger return spring of the flange insulator sleeve i8 the shank of whichy sleeve 48 seats within a concentric seating surface portion 42 f of post 42.

The horn 46 provides integrally therewith the horn post receiving base 18 providing the bearing and clamping hole 18a comprising the internal cylindric centering surface portion 18h, and the endwise disposed abutment surface 1&0 formed in a plane radial upon the axis of centering surface 18h. The hole 18a is further formed Aat the other end thereof with an internal conical centering surface and clamping area 18d with its conical axis coincident with that of surface 18h. rIhe surface '10b is complementary to surface 42a so as to slide thereonto and to receive axial alignment support therefrom, and when cylindrical it may provide rotary bearing support for the purposes of adjustment. The other end of horn 46 provides means 18e of attachment thereto for a tip holder by which tip 50 may be positioned upon the axis of surfaces 18h and 18d. The clamping-nut 45 is sleeve-like and ypro-. vides atone end thereof concentric coaxial external cone taper surface 45al and internal thread 45. Surface 45g is driven againstthe surface 'I3 to which it is complementary in that both conic surfaces are of the same angularity to their respective axes, by threads 45h and 42d, the nut being provided with suitable wrench engageable surfaces such as holes 45e for a Spanner wrench.

In the electrodynamics of welding the welding current circuit carries very high values of current, the welding heat effectiveness of which is proportional to the square of the value of current actually flowing. The low voltages generated in the welding circuit may easily be dissipated at regions where the dissipation is useless and wasteful, as well as productive of requirements for a transformer and other components adequate to provide for the waste as well as the useful energy dissipated at the welding tips. For this reason I prefer to provide the welding current circuit with a minimum number of pressure connectable components, and wherever convenient use only mere pressure connections in the circuit at the tips where welding occurs. I prefer, for example to make all connections of integrated metal bodies in lieu of which at times it is necessary to make them of flexible cables joined to other components at least by surely and permanently bolted separable pressure connections such as where such flexible cables should be readily replaced at intervals due to the breakage of individual strands thereof. In this way a minimum o1' the driving electromotive force and heat energy are dissipated in the circuit at regions other than at the work, where the maximum voltages are therefore available to effect the weld.

Accordingly, the electrode structure just previously described is firmly secured together with the nut 45 firmly electroconductively contacting surface 18d and threads 45h and driving the con-- tact abutment surface 18e toward and in some cases into firm abutment with the surface 42h.

The other important function of this clamping action is to always center the horn on the axis of reciprocation of the plunger 4l so that, once the Welder tips are axially aligned, they resume exact alignment in any clamped position to which horn 46 may be rotated and clamped after loosening of nut 45. It is clear, therefore, that the bearing of horn 46 is an adjustment bearing and not a bearing of free rotation while current flows. The Ihigh pressure clamping action between nut 45, the horn base I8 and/or the annular post 42 makes for a very high conductivity pressure formed joint and for a minimum of voltage and heat loss at this adjustable joint. It will be evident that the greater the number of such joints there are in a circuit the greater must be the number of secondary inductors to achieve a given welding current in the circuit, other factors remaining equal.

It should be observed that no rotation is required for the plunger 4I in the insulating sleeve bearing 48.

As applied to the Welder frame 506 in Fig. 23 the circuit components 42 and 18 grip an annular lip 50611 of the frame therebetween. Post 42 has integrally formed therewith a separable connector lug 42g to which the plunger inductor 30 is connected by a flexible conductor strap and by bolt structure. The annular post 42 also provides a recess therebetween and surrounding the plunger 4| and between sleeve 48 and the inductor 30 through which a plunger return spring E2 extends to hold sleeve 48 in place as well as to receive stoppage thereat to resist welding movement of the plunger.

It will be observed that in Fig. 23, as well as in modifications of other iigures, the release and/or removal of any horn 46 from the annular horn post @2 in no way disturbs the horn post 42 and its mechanical and electrical connections to the inductor of the welding current circuit.

In the other illustrations of the connector post 42 it is directly integrated with and in the rigid frame attached, or housing forming portion, of the current inductor with the inductor circuit being completed to the movable inductor from some portion of said rigid frame inductor by a flexible conductor, the flexible conductor being employed at any of several regions in the circuit as is made more clear by comparing the like positions of a short flexible cable section for the circuit in Figs. 1 and 23 as joining the annular post 42 to the beginning of an almost completely reciprocating inductor 36 with the modifications of Figs. 17, 18 and 19 wherein only the plunger 460-464 is movable and constitutes but about one-third of one secondary winding turn as compared to about one and two thirds of the secondary winding turn formed by the rigid parts 412, 4|8, 420, 442, 44B, 444, and 446 to which later component it is joined by the iiexible cable circuit component 410.

As seen in Fig. 2 the movable portion of the secondary circuit inductor is about one turn joined by short iiexible cable circuit components 94 to a second divided full rigid turn which is rigidly attached to the horn post 42; but in Fig. 13 only a small portion of the inductor circuit is of the rigid inductor material suitable for force transmission, the greater part of the inductor being provided in turns of iiexible cable 186.

I claim:

1. A welding horn having a generally spiral shape and having welding electrodes adjacent its extremities disposed toward each other along the axis of the spiral, one of said electrodes being stationary and extending to a point along said axis substantially coaxially with a region on the spiral one-half convolution displaced from the stationary electrode.

2. An electrical welding tool comprising, in combination: a transformer, a hole through said transformer, means providing xed and`movable welding tips positioned adjacent said transformer at one end of said hole, a motor positioned adjacent said transformer at the other end of and outside of said hole, and means extending freely through said hole and spaced from the transformer hole surfaces and extending to the movable welding tip and to the motor for driving the tip by the motor.

References Cited in the file of this patent UNITED STATES PATENTS c Number Name Date 2,041,913 Fassler May 26, 1936 2,126,903 Martin Aug. 16, 1938 2,236,162 Von Henke Mar. 25, 194i 2,269,726 Martin Jan. 13, 1942 2,457,606 Senn Dec. 28, 1948 FOREIGN PATENTS Number Country Date 697,193 Germany Oct. 8, 1940 

